Meanwhile back in the basement - Central Plains

Discussion in 'Some Assembly Required' started by Tanshanomi, Oct 23, 2019.

  1. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    When I'm frustrated by not being able to spend time in my shop, I cruise Ebay for parts. I bought a fuel tank for the Retroblaster-KTM-Bobber-Thing. For $55 shipped, not a bad deal. It's for a CFMoto CF125 Pango (Erroneously referred to on Ebay as "CFMOTO Mandrill"). Not a bolt-up fit by any means, but it'll work.

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  2. TUCKERS

    TUCKERS the famous james

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    Everything about a twin downtube twin shock frame just makes me smile. Love it. Visions of Manx Norton spinning around my brain. I could see a big single cylinder 4 stroke in there...I'm quite partial to the DR650 engine myself...it's such a good looker. With that space you of course need a unit construction four stroke or a hefty 2smoker.
  3. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    I used my HF Titanium 125 to tack The Bride's frame tubes this morning before work. It was my first time striking an arc with the thing and, for FCAW, it works surprisingly well. It'll never make a real welder out of me [If you gotta grind down your welds, you're a "grinder," not a "welder"], but for simple plug welding and a couple of tacks, it was easy-peasy-cheddar-cheesy. I'll eventually take it to my local welding guy to get finished correctly, but that can wait for now; I have the tank mounts and rear suspension to do, and those will require additional welding. In the meantime, it's on to fabricating the engine mount.

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  4. Kai Ju

    Kai Ju Long timer Supporter

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    Got any info on that belt sander ?
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  5. TUCKERS

    TUCKERS the famous james

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    Looking good! Great work.
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  6. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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  7. Kai Ju

    Kai Ju Long timer Supporter

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    quick search revealed these:

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  8. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    I didn't want the hassle of attaching and detaching my angle grinder. I've had it about 2 years and I've used it often enough that I'm glad I spent a little extra for the added convenience.
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  9. Kai Ju

    Kai Ju Long timer Supporter

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    Makes perfect sense, didn't even think about that aspect.
  10. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    There's a saying, "Mistakes are easy to make, so make them as easily as possible."*
    Therefore, I'm developing my engine mount with a series incremental mock-ups, using easy-to-fabricate materials. As of this morning, I've moved from cardboard, to scraps of pine board, to now thin-wall alloy square tube and hardboard. In the process, I'm refining the specific requirements for the engine mount. I already know a couple of things that will need to change in the next iteration.

    *Okay, so it's not actually "a saying." Nobody says that. I just came up with it this morning, but I thought it was terribly clever.


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  11. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    P.S. I love rivnuts.
  12. TUCKERS

    TUCKERS the famous james

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    I love CAD.....cardboard aided design
  13. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    Well, this sucks. Looks as though I'll need to put "The Bride" on hold for about six weeks. Oh well, time build a Bultaco engine, I suppose!

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  14. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    With my press brake backordered for a month, I had time to consider alternatives. I decided to pivot and go with a bolted-up alloy arrangement, rather than the folded steel box I had imagined previously. The supplies needed are trickling in.

    I don't have a chop saw or band saw, and I wasn't looking forward to hacksawing through 8 inches of 1/2" thick 6061 aluminum. Several people online had good results with circular saw blades designed specifically designed for cutting aluminum. I was skeptical; as a rule, cutting metal with a saw designed for wood is a no-no. However, I decided that for $20, it was worth a shot. Even if I just able to get a good, straight, perpendicular score across the metal, it would help me cut straight with the hacksaw.

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    I swapped out the blade in my sliding miter saw and used the adjustable depth stop to make a series of approx. 1/8" deep passes. That was probably conservative. It cut effortlessly—no bogging, no burning, just plenty of little chips flying out the back of the saw. The resulting cut was really clean. I'm really surprised how well it works. I should have tried this long ago.

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    Here's the base plate, ready to drill and bolt into the frame.

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    Bolted to this will be two angled vertical plates that will, in turn, bolt to the engine. I have 7/8" thick 6061 arriving today. They will look similar to this pair of commercial kart engine mounts—only lots cruder, most likely.

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  15. TUCKERS

    TUCKERS the famous james

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    Good job!
  16. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    Making progress, but taking it slow, trying desperately to not end up with something misaligned. "Measure twice, cut once", as they say -- or in my case, "Measure as many times as you want and still cut it wrong."

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  17. TUCKERS

    TUCKERS the famous james

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    That's quite humorous.....
  18. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    I snuck up on straight, true, and even this morning. Between the circular saw and the bench sander, I eventually got there without wasting any metal stock, so that goes in the W column as far as I'm concerned. (The left mounting plate looks undercut, but I accidentally inverted it for the photo below; the angle at the rear actually goes the other way.)

    I plan on using socket head through-bolts at the front. At the rears, I will drill the aluminum for 8mm helicoils. Likewise at the bottom, where the vertical blocks will bolt to the base plate.

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    The engine has to sit in one specific location where the starter motor, the bottom of the CVT plate, the spark plug cap, cylinder, and the intake/exhaust ports are all clear of the frame, and the drive sprocket aligns with the idler and rear sprocket.

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  19. TUCKERS

    TUCKERS the famous james

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    I'm going to sneak up on my project today...use the element of surprise to win!
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  20. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    With the engine positively located, the three sprockets all line up — Yay!
    I think the idler sprocket on the swingarm pivot will work fine.
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